MAKING THE WALL BOX

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					                       MAKING THE WALL BOX

After the material has been dimensioned, lay out the scrollwork
on the back. Once the location of the top circle is
established but before the scrollwork is cut out on the band
saw, cut a dado across the grain on the back side of this
circle. This dado should extend well below the narrow
throat on which the top circle is resting. Fit a strip of
vertically grained wood into that dado and fasten with
3/8" no. 4 wood screws. Then, cut out the scrollwork.
After establishing the angle for the two sides, cut the
top edge of the front to match. You can do this on the
table saw by ripping the piece to width on a blade canted
at the proper angle, but I find it quicker to create that
angle with a few strokes of a hand plane. Use a bevel gauge
to check progress during this operation.
Remember that the angle on the box's front piece is not
cut to match the height of the sides at their front most
point because the highest point of the angle on the front
piece will join the sides 7/16" back from the frontmost
point. The 7/16" measurement allows 3/8" for the
thickness of the dovetail joint, plus a 1/16" surplus which
will be sanded away to make the joint flush.
Cut the dovetails at each of the box's corners. After
sanding these flush, give the bottom of the box and the
lid shaped edges on a shaper or a table-mounted router.
Install the bottom with wood screws passing through oversized
holes in the bottom. These holes are oversized to
allow the part to expand and contract in response to seasonal
changes in humidity.
The narrow top, to which the lid will be hinged, is the next
consideration. Form the angled front edge, which will abut
the angled back edge of the lid, with a hand plane. Then
fasten it to the case with several screws passing through
the back of the box. Although 1 felt it unnecessary because
of the top's narrow width, this part might be more securely
fastened by installing some short glue blocks underneath the
joint between the top and the sides of the case.
Using a hand plane, fit the back edge of the lid to the
angle already established on the front edge of the box's
top. Do this gradually so that it can be fit against the front
edge of the top without gapping at the ends.
Next, install the hinges. The pair shown in the photo are
Brainerd antique brass hinges from which the tails on the
upper leaves have been cut to allow those upper leaves to fit
on the narrow width of the top of the box.
Remove the hinges and give the box a final sanding and
several coats of finish.

				
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posted:2/5/2013
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